Beko CLEARPOINT S040 Installation instructions

en-us
CLEARPOINT® Water separator
08-384
Installation and operation instructions
> S040
> S050
> S075
> M010
> M015
> M020
> M022
> M025
> M030

Table of contents
1. General.............................................................................................................................................4
1.1 Contact............................................................................................................................................................4
1.2 Installation information and operating manual.....................................................................................4
1.3 Additional valid documents........................................................................................................................4
1.4 Explanation of symbols and pictograms used........................................................................................5
1.4.1 In documentation..............................................................................................................................5
1.4.2 On the device.....................................................................................................................................6
1.5 Intended use...................................................................................................................................................7
1.6 Foreseeable misuse ......................................................................................................................................8
1.7 Warranty and liability...................................................................................................................................8
1.8 Target audience and personnel .................................................................................................................9
1.9 Responsibilities of the operator ................................................................................................................9
2. Safety information........................................................................................................................ 10
2.1 General information...................................................................................................................................10
2.2 Safety instructions......................................................................................................................................11
3. Transport and storage................................................................................................................... 12
4. Product information ..................................................................................................................... 13
4.1 Product description....................................................................................................................................13
4.2 Product overview ........................................................................................................................................13
4.3 Product identication ................................................................................................................................14
4.4 Functional description...............................................................................................................................16
4.4.1 Water separation.............................................................................................................................16
4.4.2 Condensate drainage through the oat drain..........................................................................17
4.4.3 Condensate discharge by BEKOMAT.........................................................................................18
4.5 Scope of delivery ........................................................................................................................................18
4.6 Name plate ...................................................................................................................................................19
4.7 Stamp water separator insert...................................................................................................................20
5. Technical data ............................................................................................................................... 21
5.1 Separator performance data ....................................................................................................................21
5.2 Materials .......................................................................................................................................................23
6. Dimensions.................................................................................................................................... 24
7. Installation .................................................................................................................................... 26
7.1 Warning.........................................................................................................................................................26
7.2 Installation work..........................................................................................................................................27
8. Commissioning.............................................................................................................................. 29
8.1 Commissioning work..................................................................................................................................29
9. Maintenance and servicing........................................................................................................... 30
9.1 Maintenance schedule...............................................................................................................................30
9.2 Cleaning ........................................................................................................................................................30
9.2.1 Warning.............................................................................................................................................30
9.2.2 Cleaning work ..................................................................................................................................31
9.3 Visual inspection.........................................................................................................................................31
9.4 Exchange the oat drain............................................................................................................................32
9.5 Exchange the water separator insert .....................................................................................................36
9.6 Leak test........................................................................................................................................................39
10. Shutting down............................................................................................................................. 40
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11. Disassembly ................................................................................................................................ 41
11.1 Warning.......................................................................................................................................................41
11.2 Disassembly work.....................................................................................................................................42
12. Disposal....................................................................................................................................... 44
12.1 Warning.......................................................................................................................................................44
12.2 Disposal work ............................................................................................................................................44
13. Spare parts and accessories........................................................................................................ 45
13.1 Replacement parts....................................................................................................................................45
13.2 Accessories top attachments.................................................................................................................45
13.3 Accessories bottom attachments.........................................................................................................46
14. Troubleshooting and repair / FAQ ............................................................................................. 47
15. Product specications and certications .................................................................................. 48
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1. General
1.1 Contact
Manufacturer Service and tools
BEKO TECHNOLOGIES GmbH
Im Taubental 7 | D-41468 Neuss
Tel. + 49 2131 988 - 1000
[email protected]om
www.beko-technologies.com
BEKO TECHNOLOGIES GmbH
Im Taubental 7 | D-41468 Neuss
Tel. + 49 2131 988 - 1000
[email protected]
www.beko-technologies.com
1.2 Installation information and operating manual
INFORMATION Copyright protection
iThe content of this installation and operating manual, in the form of text, images, photos,
drawings, diagrams, and other illustrations, is copyright protected by the manufacturer. This
applies in particular to copies, translations, microlm versions, and saving and processing this
document in electronic systems.
Publication date Revision version Reason for change Scope of change
10/31/18 00_01 Change to standards and
directives Initial creation
This installation and operating manual, referred to in the following as the manual, must be legible and must be stored
near the product at all times.
The manual must be included if the product is sold or handed over to another party.
NOTE Observe the manual!
This manual contains all basic information required to safely operate the product, and operators
must read the manual before carrying out all work. Otherwise hazards could occur for personnel
or materials, and functional or operating disruptions could occur.
1.3 Additional valid documents
This manual describes all steps required to install and operate the CLEARPOINT®water separator.
Further information on installing and operating accessories is provided in the following installation and operating
manuals:
• BEKOMAT® 20
• BEKOMAT® 20 Vario
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1.4 Explanation of symbols and pictograms used
The symbols and pictograms used in the following indicate important and safety-related information that must be
observed in handling the product and to ensure safe and optimal operation.
1.4.1 In documentation
Symbol/pictogram Description/explanation
General hazard symbol (danger, warning, caution)
Pressurized system
Observe the installation and operating manual
General instructions
Use FFP 3 respirator
Wear safety shoes
Wear protective gloves (liquid-resistant)
Wear hearing protection
Wear safety glasses with side protection (goggles)
General information
i
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1.4.2 On the device
Symbol/pictogram Description/explanation
General hazard symbol (danger, warning, caution)
(This symbol is indicated on the type plate and maintenance sticker)
Observe the installation and operating manual
(This symbol is only indicated on the type plate)
Maintenance sticker
This sticker contains a stylized illustration indicating that the user manual must be read
before completing maintenance work and that the product must be depressurized before
maintenance work.
Flow
Stamp water separator insert
(This stamp is on the base of the water separator insert and indicates the direction of ow.
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1.5 Intended use
CLEARPOINT® Water Separator and Accessories
The CLEARPOINT®water separator, also referred to in the following document as the separator, serves to separate drops
of liquid and solid particles in pressurized gas systems.
Any other use besides that described in this manual is deemed improper and poses a risk to personnel and the
environment.
• Only use the separator and accessories within the operating parameters and agreed delivery conditions indicated in
the technical data.
• Only use the separator and accessories in a pipeline system designed to handle the technical data indicated, with
appropriate connections, pipe diameters and installation space.
• Only use the separator and accessories to process uid group 2 compressed gases free from aggressive and corrosive
components in accordance with Pressure Directive 2014/68/EU.
• Only use the separator and accessories in non-explosive areas.
• Only use the separator and accessories in areas not exposed to direct sunlight or heat sources and in areas not in
danger of frost.
• Only combine the separator and accessories with recommended products indicated in the manual from
BEKO TECHNOLOGIES GMBH.
Before using the separator, the operator must ensure that all conditions and requirements for the intended use have
been fullled.
The separator is designed only for stationary use in a commercial or industrial area. All work described for mounting,
installation, operating, removal and disposal may only be carried out by qualied professional technicians.
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1.6 Foreseeable misuse
If the separator or accessories are used in a manner other than as described in the “Proper use” chapter, this is
considered foreseeable misuse. Foreseeable misuse includes using the product in a manner not intended by the
manufacturer or suppliers, but which may occur due to foreseeable human behavior.
Foreseeable misuse includes:
• Completing modications of all kinds, in particular changing the design or process technology, since this may result
in personal injury and property damage as well as functional and operating disruptions.
• Disabling or failing to use available or recommended safety equipment.
• Using compressed gases for preparation that are not included in uid group 2 in accordance with DGRL 2014/68/EU
or contain aggressive components. In case of doubt, complete a gas / condensate analysis.
This list does not claim to be exhaustive, since it is not possible to indicate all possible misuses in advance. If the
operator knows of misuses of the separator or accessories that are not listed here, the manufacturer must be informed
of these promptly.
1.7 Warranty and liability
The operator and user must take the proper use into consideration. The operator shall be solely responsible for any
action not described here and any use going beyond that described as proper use.
All warranty shall be voided, if the separator is used improperly, for a purpose other than the intended or is operated
outside the limits specied in the technical data. In such cases, the manufacturer shall also reject any liability for
damages.
Improper operation includes:
• Technically inappropriate installation, commissioning, maintenance or operation
• Use of defective components
• Failure to observe the safety-relevant information, usage steps and instructions included in this manual
• Completing modications of any kind, in particular design or process technology changes to the product
• Use of third-party spare parts or accessories that have not been approved by the manufacturer in completing
maintenance and repair work
• Failure to observe maintenance and inspection intervals
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1.8 Target audience and personnel
This manual is directed towards the following professional technicians assigned to work on the separator or accessories.
INFORMATION Personnel requirements
iPersonnel may not complete any work on or with the separator or accessories if they are
under the inuence of drugs, medications, alcohol or other substances that could impair their
awareness.
Professional technicians - Transport and storage
Transportation and storage technicians are personnel whose training, professional experience and qualications
have given them all the skills necessary to safely complete any actions associated with transportation, to recognize
potential hazards independently and take measures to prevent those hazards.
These skills include, in particular, experience in handling hoists, forklifts and lifting equipment and devices as well as
an understanding of regional applicable laws, standards and directives related to transportation and storage.
Compressed gas technology technicians
Compressed gas technology technicians are personnel whose training, professional experience and qualications have
given them all the skills necessary to safely complete any actions associated with compressed gases and pressurized
systems, to recognize potential hazards independently and take measures to prevent those hazards.
These skills include, in particular, experience in handling measurement, control and regulation technology as well as an
understanding of regional applicable laws, standards and directives related to compressed gas technology.
1.9 Responsibilities of the operator
The responsible operator must ensure the following to avoid accidents, faults and environmental impacts:
• Check before all actions whether this manual matches the product.
• Ensure the product is used, maintained, and repaired properly.
• Ensure that all applicable legal specications, safety provisions and accident prevention regulations are complied
with.
• Ensure that all specications and operating instructions for safe work and instructions for how to respond to
accidents and res are accessible at the work site to personnel at all times.
• Ensure the product is used with recommended and functional safety equipment and that this equipment has not
been deactivated.
• Ensure all assembly, installation and maintenance work is only carried out by qualied professional technicians.
• Ensure the recommended personal protective equipment is available and is used.
• Ensure suitable technical safety measures are taken to ensure the permitted operating parameters are not exceeded
and are met.
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2. Safety information
2.1 General information
Safety information warns of hazards related to handling the product. In the instructions, warning information is stated
before the steps that could pose a hazard to personnel or the surrounding area.
This safety and warning information must always be observed to avoid accidents, personal injury and property damage,
and operational disruptions.
Structure of the safety information
Content of the safety information structured according to the SAFE principle:
S - Safety symbol and signal word
A - Type and source of danger
F - Possible consequences for failure to observe the hazard in the order of severity
E - Measures to avoid the hazard
Structure of the safety information:
SIGNAL WORD Type and source of danger!
Safety indications
Possible consequences if the hazard is not observed
• Measures to avoid the hazard
Signal words according to ISO 3864 and ANSI Z.535.6
DANGER Imminent danger
Consequences of non-compliance: Death or severe personal injury
WARNING Imminent danger
Consequences of non-compliance: Death or severe personal injury are possible
CAUTION Potential danger
Consequences of non-compliance: injury and/or damage to property
NOTICE Additional notes, tips and hints
Consequences of non-compliance: Disadvantages in operation and during handling and
maintenance.
No hazard to personnel or safe operation.
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2.2 Safety instructions
Always observe the safety and warning information provided to avoid accidents, personal injury and property damage,
and operational disruptions.
The personal protective equipment indicated in the safety information must be selected by the operator based on the
system parameters and properties and must be provided.
DANGER Operating outside of permitted limit values!
Operating the product outside of the permitted limit values and parameters and prohibited
modications and changes pose the risk of death or a hazard of severe injuries.
• Observe the limit values, operating parameters and maintenance intervals and set-up and
ambient conditions indicated on the type plate and in the manual to ensure safe operation of
the product.
• Check whether operating parameters are changed or restricted through the use of
accessories.
• Only use the product according to its intended use.
DANGER Pressurized system!
The risk of death or severe injuries exists in case of contact with fast or sudden exiting
compressed air or due to bursting system parts.
• Only work on the system when it is depressurized and secure the system against unintended
restart.
• Set up a safety zone around the system when carrying out any assembly, installation,
maintenance and repair work.
• Before pressurizing the system, check and tighten all pipe connections.
• Pressurize the system slowly.
• Avoid pressure surges and high pressure dierentials.
• Install all pipelines without mechanical tension. Avoid vibrations occurring in the pipeline
network by using vibration dampers.
• Carefully observe the installation and operating instructions in this manual.
• Carefully observe inspection and maintenance intervals.
• Permanently install inlet and outlet lines.
• Do not make modications on the product.
DANGER Use of incorrect replacement parts, accessories or installation materials!
The use of incorrect replacement parts, accessories or installation material or operating and
auxiliary materials may result in death or severe injuries. This may also cause functional or
operating disruptions or material damage.
• Only use undamaged original parts, auxiliary and operating materials for all installation and
maintenance work as indicated by the manufacturer.
• Only use ttings and connection elements permitted for the specic application and suitable
tools in proper condition.
• Only use cleaned pipelines free from dirt and corrosion.
WARNING Failure to use personal protective equipment!
The failure to use personal protective equipment or the use of defective personal protective
equipment may result in accidents or injuries while working on the product.
• Wear personal protective equipment recommended for the specic task in proper condition
when completing any work on the product.
• Regularly check personal protective equipment for proper function and replace damaged
parts promptly.
WARNING Insucient qualication!
If personnel have insucient qualications, this may result in accidents, personal injury and
property damage as well as operating disruptions while working on the product.
All work on the product may only be carried out by suciently qualied professional technicians.
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3. Transport and storage
WARNING Insucient qualication!
If personnel have insucient qualications, this may result in accidents, personal injury and
property damage as well as operating disruptions while working on the product.
The work on the product described in the following may only be carried out by transportation
and storage technicians and must be documented.
CAUTION Improper transportation or storage!
Improper transportation or storage may result in personal injury or property damage.
• Always wear gloves when working with packaging materials.
• Use personal protective equipment, check it regularly for proper function and replace
damaged parts promptly.
• The product must only be transported and stored by transportation and storage technicians.
• Handle the packaging and product carefully.
• Package all parts with suitable materials in a shock-resistant manner.
• Transport and handle packaging according to the label (observe hoist attachment points and
center of gravity, keep alignment vertical, do not throw, etc.)
• Use proper, functional transportation equipment and hoists.
• Observe permitted transportation and storage parameters.
• Do not store the product exposed to direct sunlight and heat sources.
NOTICE Handling packaging materials!
The improper disposal of packaging materials may result in environmental damage.
• The packaging material is recyclable.
• Dispose of packaging materials in accordance with the regional laws, directives and
guidelines of the country of use.
NOTICE Transportation and storage notices!
The product must
• be stored in the original packaging in a closed, dry, and frost-free room. The ambient
conditions, transportation and storage parameters may not exceed or fall below the
information in the Technical Data chapter.
• Even when packaged, protect the device against the elements.
• While in storage, secure the device so that it cannot topple over or fall, and protect it
against vibration.
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4. Product information
4.1 Product description
CLEARPOINT®water separators are used to separate drops of liquid and solid particles in compressed gas pressurized
systems.
The condensate collected during separation can be drained manually or automatically.
4.2 Product overview
The separator consists of the following components:
4
5
7
8
Fine filter
Type:
Material-no.:
Lot:
Year:
Element:
Elementmat.-no.:
Min./max.working
temperatureTS:
Max.working
pressurePS:
Volume:
Testpressure PT:
Connection:
S040FWF
4002618
201420
2014
04F
4002707
+2... 60 °C / +35 ... +140 °F
1,5.. 16 bar / 22 ... 232 psi
asd
23bar / 334 psi
pipeG 3/8
drainG 1/2
Fluidgroup2
PED97/23/EC / Cat. -
Beko TECHNOLOGIES
http://www.beko-technologies.com
2
6
3
1
2a
Position no. Explanation / description
[1] Inlet on the separator head,
[2] Outlet on the separator head also designated with 2a
[3] Housing head
[4] Water separator insert (WS insert)
[5] Safety runner with locking screw
[6] Name plate
[7] Housing body
[8] Maintenance sticker
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4.3 Product identication
The product designation is indicated on the type plate and consists of numbers and an abbreviation. Each abbreviation
stands for a separator component and is divided into the following categories:
[1] = Size: Housing
[2] = WS insert
[3] = Top attachments
[4] = Bottom attachments
The following section explains the product designation using the example “S040WWB”:
S040WWB
2
2
3
3
4
4
1
1
Bottom
attachments
Top attachments
WS insert
Size: Housing S040
S050
S075
M010
M015
M020
M022
M025
M030
W
B
F
W
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Top attachments
Position no. Abbreviation Designation
[3] W No display device
Water separator inserts
Position no. Abbreviation Designation
[2] W Water separator
Position no. Model series Size Designation
[1]
S 040
Size Housing
S 050
S 075
M 010
M 015
M 020
M 022
M 025
M 030
Bottom attachments
Position no. Abbreviation Designation
[4] B BEKOMAT®20
F Float drain, open when depressurized (NO - normally open)
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4.4 Functional description
4.4.1 Water separation
The compressed gas enters the inlet on the separator head [1] and passes into the water separator. A specially formed
swirl insert [2] makes the compressed gas rotate quickly. The centrifugal forces generated press the condensate particles
against the housing wall. Gravity causes the condensate particles to ow down into the collector chamber [3], from
which they are drained.
1
2
3
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4.4.2 Condensate drainage through the oat drain
Float drains are mechanical automatic condensate drains whose closing mechanism is triggered by the buoyancy of a
oat body [1]. When the condensate [2] in the container raises above a certain level, the buoyant lift of the oat body
[1] opens the outlet channel [3] for the condensate. The oat closes again when the condensate [1] drops below a
certain level: A small amount of condensate remains in the container.
Two dierent oat drains are used to drain the condensate:
• Open when depressurized ([NO] normally open) - at an operating pressure ≤ 0.5 bar(ü) the oat drain opens
• Closed when depressurized ([NC] normally closed) - the oat drain is closed even at an operating pressure of 0 bar(ü)
Float drain opens Float drain closes
3
2
1
3
2
1
Both types of oat drain are delivered in the position >>Automatic drainage<<. The knurled-head screw is screwed down
to the stop.
To test the drainage function or release pressure to the separator to complete maintenance, the oat drain can be set to
the position >>mechanically open<<. To do so, unscrew the knurled-head screw counterclockwise (left-hand turn) to stop.
Automatic drain Mechanically open
INFORMATION Condensate discharge!
iCondensate discharge is dependent on the product combination and may vary.
For further information on possible product combinations see “4.3 Product identication” on page 14.
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4.4.3 Condensate discharge by BEKOMAT
Condensate may also be discharged via the automatic BEKOMAT® steam trap.
Further information is provided in the BEKOMAT®installation and operating manual.
4.5 Scope of delivery
The following table shows the scope of delivery for the separator.
Image Description/explanation
Separator
Installation and operation instructions
INFORMATION Possible product combinations!
iThe scope of delivery may vary depending on the product combination.
For further information on possible product combinations see “4.3 Product identication” on page 14.
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4.6 Name plate
The type plate is located on the housing, and provides identication and operating parameters for the separator.
Provide this data for system identication when contacting the manufacturer or supplier.
Example illustration
Position on type plate Description
Water separator BEKO separator designation
Type Sales designation
Material-no. Material number
Lot Lot
Year Year of manufacture
Element Water separator insert
Element mat-no. Material number water separator insert
Min./max. working temperature TS Min./max. working temperature range
Max.working pressure PS Max. working pressure range
Volume Housing volume
Test Pressure PT Test pressure
Connection Threaded connections
pipe G 1/2 Inlet pipe threaded connection
drain G 1/2 Condensate drain threaded connection
Fluid group 2 Fluid group 2 according to PED 2014/68/EU
PED2014/68/EU / Cat. - Category in accordance with Pressure Directive
2014/68/EU
NOTICE Handling the type plate!
Do not remove or cover the type plate, and protect it against damage.
For more information regarding the symbols printed on the type plate, see “1.4 Explanation of symbols and pictograms
used” on page 5.
Water separator
Type:
Material-no.:
Lot:
Year:
Element:
Element mat.-no.:
Min./max. working
temperature TS:
Max. working
pressure PS:
Volume:
Test pressure PT:
Connection:
S050WWF
4004363
201851
2018
04W
4004320
+2 ... 60 °C / +35 ... +140 °F
1,5 ... 16 bar / 22 ... 232 psi
0,31 l
23 bar / 334 psi
pipe G 3/8
drain G 1/2
Fluidgroup 2
PED2014/68/EU / Cat. -
BEKO TECHNOLOGIES GmbH
beko-technologies.com
Made in Germany
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4.7 Stamp water separator insert
The WS insert can be identied by a stamp on the element base.
1
Flow
Stamp on the base of the WS insert Stamp water separator insert
-
View of element base
Position no. Explanation / description
[1] Direction of ow
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